Beyond the Surface: Looking Inside an IH Manufacturer’s Quality Control Process

By: Dusty Ott, Contributor

SKC Inc.’s NoiseCHEK Personal Dosimeter (photo courtesy SKC Inc.)

In a market saturated with products that claim to deliver top-notch quality, how can you be sure that what you’re getting truly meets the highest standards? Given the essential use of industrial hygiene tools to help OEHS professionals keep workers healthy and safe, quality control should be the cornerstone of industrial hygiene product manufacturing, ensuring that every product produced not only meets but exceeds industry expectations.

In this article we take a peek behind the curtain at how a model industrial hygiene equipment and media manufacturer can ensure the highest quality products.

Quality Assurance: A Proactive Approach

A robust quality management system (QMS) is the foundation of producing quality products. A QMS is a structured way to minimize risks related to the quality of products produced.

Many manufacturers have quality management systems which are certified to ISO 9001:2015. One of the largest advantages of having a formal QMS is that quality standards and all processes are documented and controlled. These processes are then regularly audited, not only internally, but also by external bodies to ensure that the organization continues to manage quality in a proactive manner.

Every instrument produced by our “model manufacturer” is put through a rigorous performance test before leaving the facility; every lot of media products that require low background undergo analytical testing; and all other products are subject to in-line quality control that is built into the production process. This helps the company ensure that their customers receive quality product and that no detail is overlooked.

Innovative Technologies—Enhancing Quality

Further strengthening a company’s commitment to quality is employment of innovative measurement technologies. For example, every part used should pass through an incoming inspection process utilizing precise measurement equipment, such as digital calipers, micrometers, optical comparator, and an optical Coordinate Measuring Machine (CMM). The CMM technology allows a company to conduct multiple part checks simultaneously, ensuring that only components meeting stringent standards are used in the finished products.

It’s also beneficial if a company can utilize internally developed test equipment implemented throughout the production process. The result? A superior end-product that offers reliability and consistency—giving customers confidence.

Human Element of Quality: Employee Expertise

When taking a closer look, an observer would see that quality control isn’t just about machines and processes; it’s about people. Every employee on the production floor at our model company is trained and qualified to ensure the products they manufacture meet high standards. Through continuous on-the-job training and elective industry certifications, such as the Society of Manufacturing Engineers Certified Manufacturing Associate (CMfgA) and IPC-A-610 CIS, team members are empowered to identify and rectify potential issues before they affect the final product. The end-result is that the team is not just knowledgeable but also deeply committed to delivering a quality product.

The AirChek® TOUCH Sampling Pump from SKC Inc. (photo courtesy SKC Inc.)

Rigorous Testing and Industry Standards

The model manufacturer also adheres to multiple international standards for both product requirements and quality management systems, including ISO 9001:2015, ISO/IEC 17025:2017 (for calibration laboratories), and ISO 80079-34:2018 for products used in explosive atmospheres. Each of these standards requires a periodic audit by an external body for continued certification. These standards and certifications are more than just benchmarks; they are a testament to an unwavering commitment to quality.

Success Stories: Quality in Action

Customer feedback is considered a vital component of the quality control process, driving continuous improvement and innovation. A good quality assurance team thoroughly reviews every suggestion, complaint or idea and, if an issue is identified, the team promptly initiates a plan to address it. This proactive approach ensures issue resolution and prevents the problem from recurring, demonstrating strong commitment to delivering exceptional products.

A prime example of this commitment might be how companies respond to customer feedback on clips (in our model case, for noise dosimeters). When users reported unexpected wear and tear, the manufacturer quickly re-engineered the design and provided updated clips to all affected customers, reinforcing a reputation for quality and customer care.

Additionally, this model manufacturer has made software tweaks based on customer suggestions, enhancing product functionality to better meet their needs. These successes illustrate how dedication to quality directly benefits customers, solidifying trust in the products.

Challenges and Future Goals: Strive for Excellence

Maintaining high quality is not without its challenges. A model manufacturer continually looks ahead and works to be more proactive in identifying and resolving quality issues. The goal is to build a world-class manufacturing operation that supports the essential mission of protecting workers and the environment worldwide.

Key Takeaways

Quality isn’t just a buzzword; it should be a cornerstone for industrial hygiene equipment and media manufacturers—a core value that permeates every aspect of operations. As demonstrated by our model manufacturer, proactivity, innovative technologies, employee development, adherence to industry standards, rigorous testing, internalizing customer feedback, overcoming challenges and promoting a commitment to excellence are things industrial hygienists and other OEHS professionals should look for when choosing the manufacturer of the important tools they use to help protect the health and safety of workers. IHW

Dusty Ott, CIH, is a Corporate Industrial Hygienist for SKC Inc.

SKC Inc. has over 60 years of specialization in industrial hygiene product design, manufacture, sales and support. From air sampling pumps to noise dosimeters, size-selective samplers and various sampling media, such as filter cassettes and sorbent tubes, their products are crafted to meet the precise needs of industrial hygiene and other OEHS professionals who cannot afford to compromise on safety or quality.